# US 2014/0190952 A1 · Aluminum alloy welding wire

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- Number: US 2014/0190952 A1
- Document ID: US20140190952A1
- Status: Published application
- Kind: A1
- Application number: 14/161,432
- Filed: 2014-01-22
- Published: 2014-07-10
- Earliest claimed: 2010-02-10
- Assignees: Illinois Tool Works Inc.
- Applicants: Illinois Tool Works Inc.
- Inventors: Bruce Edward Anderson; Christopher Hsu
- Web page: https://patentgrep.com/patent/US20140190952A1

## CPC

- B23K 35/286: {Al as the principal constituent}
- B23K 35/0261: {Rods, electrodes or wires}
- B23K 35/28: with the principal constituent melting at less than 950°C
- B23K 35/288: {with Sn or Zn}
- B23K 35/383: {mainly containing noble gases or nitrogen}
- B23K 35/40: Making wire or rods for soldering or welding
- C22C 21/02: with silicon as the next major constituent
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- C22C: ALLOYS (treatment of alloys C21D, C22F)

## Abstract

A composition for welding or brazing aluminum comprises silicon (Si) and magnesium (Mg) along with aluminum in an alloy suitable for use in welding and brazing. The Si content may vary between approximately 4.7 and 10.9 wt %, and the Mg content may vary between approximately 0.20 wt % and 0.50 wt %. The alloy is well suited for operations in which little or no dilution from the base metal affects the Si and/or Mg content of the filler metal. The Si content promotes fluidity and avoids stress concentrations and cracking The Mg content provides enhanced strength. Resulting joints may have a strength at least equal to that of the base metal with little or no dilution (e.g., draw of Mg). The joints may be both heat treated and artificially aged or naturally aged.

## Claims

### Claim 1

A method of forming a metallurgical bond, comprising:
metallurgically bonding at least a portion of a work piece base metal and a filler metal to form the metallurgical bond, wherein the filler metal is an alloy of silicon in a weight percent of between approximately 4.7% and approximately 6.0%, magnesium in a weight percent of between approximately 0.20% and approximately 0.50%, and a remainder of aluminum and trace elements.

### Claim 2 (depends on 1)

The method of claim 1, wherein the metallurgical bond comprises less than approximately 20% of the base metal.

### Claim 3 (depends on 1)

The method of claim 1, wherein the metallurgical bond has a post-bonding transverse shear strength between approximately 25 KSI and approximately 35 KSI, and a post-bonding tensile strength between approximately 35 KSI and approximately 50 KSI.

### Claim 4 (depends on 3)

The method of claim 3, wherein the metallurgical bond has a post-bonding transverse shear strength between approximately 28 KSI and approximately 33 KSI, and a post-bonding tensile strength between approximately 40 KSI and approximately 45 KSI.

### Claim 5 (depends on 1)

The method of claim 1, comprising aluminum in a weight percent of between approximately 92.5% and approximately 95.0%, and a remainder of trace elements.

### Claim 6 (depends on 1)

The method of claim 1, wherein the trace components comprise one or more of iron, copper, manganese, zinc, titanium, beryllium, zirconium, scandium, and chromium, wherein the total weight percent of the trace elements does not exceed approximately 1.0 wt % of the filler metal.

### Claim 7 (depends on 1)

The method of claim 1, wherein the alloy comprises silicon in a weight percent of between approximately 5.0% and approximately 6.0%, and magnesium in a weight percent of between approximately 0.21% and approximately 0.50%.

### Claim 8 (depends on 1)

The method of claim 1, wherein the process for forming the metallurgical bond comprises a metal inert gas welding process.

### Claim 9 (depends on 1)

The method of claim 1, wherein the process for forming the metallurgical bond comprises a tungsten inert gas welding process.

### Claim 10 (depends on 1)

The method of claim 1, wherein the process for forming the metallurgical bond comprises a stick welding process.

### Claim 11 (depends on 1)

The method of claim 1, wherein the process for forming the metallurgical bond comprises a pulse welding process.

### Claim 12 (depends on 1)

The method of claim 1, wherein the process for forming the metallurgical bond comprises an alternating current welding process.

### Claim 13 (depends on 1)

The method of claim 1, wherein the process for forming the metallurgical bond comprises a controlled short circuit process.

### Claim 14 (depends on 1)

The method of claim 1, wherein the process for forming the metallurgical bond comprises a regulated metal deposition process.

### Claim 15 (depends on 1)

The method of claim 1, wherein the process for forming the metallurgical bond comprises an active wire process.

### Claim 16 (depends on 1)

The method of claim 1, wherein the process for forming the metallurgical bond comprises a hot wire process.

### Claim 17 (depends on 1)

The method of claim 1, wherein the process for forming the metallurgical bond comprises a cold metal transfer process.

### Claim 18 (depends on 1)

The method of claim 1, wherein the metallurgical bond comprises a weld joint.

### Claim 19 (depends on 1)

The method of claim 1, wherein the metallurgical bond comprises a braze joint.

### Claim 20 (depends on 1)

The method of claim 1, comprising performing a plurality of successive passes in which the base metal or preceding passes of the filler metal are melted and additional filler metal is deposited.

### Claim 21 (depends on 20)

The method of claim 20, wherein during at least one successive pass substantially all magnesium in the respective pass is provided by the filler metal.

### Claim 22 (depends on 1)

The method of claim 1, wherein the metallurgical bond has a strength at least equal to the base metal.

### Claim 23

A welding consumable comprising:
silicon in a weight percent of between approximately 4.7% and approximately 6.0%, magnesium in a weight percent of between approximately 0.20% and approximately 0.50%, and a remainder of aluminum and trace elements.

### Claim 24 (depends on 23)

The welding consumable of claim 23, comprising aluminum in a weight percent of between approximately 92.5% and approximately 95.0%, and a remainder of trace elements.

### Claim 25 (depends on 23)

The welding consumable of claim 23, wherein the trace components comprise one or more of iron, copper, manganese, zinc, titanium, beryllium, zirconium, scandium, and chromium, wherein the total weight percent of the trace elements does not exceed approximately 1.0 wt %.

### Claim 26 (depends on 23)

The welding consumable of claim 23, comprising silicon in a weight percent of between approximately 5.0% and approximately 6.0%, and magnesium in a weight percent of between approximately 0.21% and approximately 0.50%.

### Claim 27 (depends on 23)

The welding consumable of claim 23, wherein the welding consumable comprises a spooled or linear wire or rod.

### Claim 28 (depends on 23)

The welding consumable of claim 23, wherein the welding consumable comprises a brazing component.

### Claim 29 (depends on 28)

The welding consumable of claim 28, wherein the brazing component comprises brazing rings or paste.

### Claim 30 (depends on 23)

The welding consumable of claim 23, wherein the welding consumable comprises a cladding alloy for cladding aluminum base alloys to aluminum or aluminum alloy base metal components.